Method and apparatus for packaging articles

ABSTRACT

This application discloses a method and apparatus for stacking a plurality of articles in superposed relation and subsequently placing a plurality of full stacks of the articles into a container. The articles are initially moved in end-to-end relation in transversely spaced rows along a path and are dropped at the end of the path towards a lower support. An intermediate shuttle plate is positioned between the end of the path and the support to briefly interrupt the downward movement of the articles. The articles are then dropped and received on the support to form a stack in an area. The stacks of the articles are periodically moved along the support to a collection area. An open topped shovel is utilized to periodically remove a plurality of stacks from the support. The plurality of stacks on the shovel are then placed in a container with its top facing downwardly over the open topped shovel and thereafter rotating the shovel and container to place all of the stacks on the shovel into the container.

o United States Patent 1 [111 3,791,099

Wagner Feb. 12, 1974 METHOD AND APPARATUS FOR Primary Examiner-Robert L. Spruill PACKAGING AR'UCLES Attorney, Agent, or FirmHofgren, Wagner, Allen, [75] Inventor: Richard C. Wagner, Clarendon steuman & Mccord Hills, ll]. [73] Assignee: Integral Process Systems, lnc., Park [57] ABSTRACT F 11], This application discloses a method and apparatus for stacking a plurality of articles in superposed relation [22] Flled' 1972 and subsequently placing a plurality of full stacks of [21] App]. No 241,767 the articles into a container. The articles are initially moved in end-to-end relation in transversely spaced rows along a path and are dropped at the end of the [52] US. Cl "SE/51122265513335gait/5692i path towards a lower Support. An intermediate Shuttle Int Cl B65) B65) B65b 67/00 plate is positioned between the end of the path and d 35 62 5 162 243 the support to briefly interrupt the downward move- Ie ment of the articles. The articles are then dropped and 53/392 255 received on the support to form a stack in an area. 6 v f The stacks of the articles are periodically moved along [5 1 References cued the support to a collection area. An open topped UNITED STATES PATENTS shovel is utilized to periodically remove a plurality of 2,013,555 9/1935 Deeren 53/392 X stacks from the support. The plurality of stacks on the 2,528,463 lO/l950 Whetzell 53/255 shovel are then placed in a container with its top fac- 5,233,433 bazott et al X i g downwardly over the open topped shovel and ,4 l ieson et al X thereafter rotating the shovel and container to place all of the stacks on the shovel into the container.

2] Claims, 13 Drawing Figures PATENTEDFEB 1 2 m4 $791; 099 saw 3 BF 5 F 1 .COO CO PATENTEnHzBm I974 319L099 sum w 0F 5 Fire; .9

METHOD AND APPARATUS FOR PACKAGING ARTICLES BACKGROUND OF THE INVENTION The present invention relates to the stacking and packaging of flat articles.

In recent years, improved methods have been developed for instantly freezing food and non-food products in a continuous process. One method that has found a remarkable degree of commercial success involves flash freezing of articles in a substantially continuous process as the articles are moving along a path within a chamber. An exemplary method of flash freezing is disclosed in J. D. Harper et al., US. Pat. No. 3,277,657, assigned to the assignee of the present invention.

When processing flat articles, such as hamburger patties, in flash freezers of the type disclosed in the above patent, difficulties have been encountered in accommodating the articles at the speeds at which they emerge from the eiiit end of the processing chamber. Heretofore, it has been customary to provide an appropriate number of employees at the end of the freezer to package the plurality of articles as they emerge from the freezer unit.

However, because of the increased capacity of freezer units of this type, it has become impractical and impossible to have sufficient employees in the restricted are at the end of the freezer unit to remove the articles as they emerge from the unit. The most pertinent prior art of which applicant is aware are U. S. Pat. Nos. 3,392,853 and 3,525,443.

SUMMARY OF THE INVENTION The present invention obviates the above problems by providing a stacking apparatus that is capable of being used in conjunction with a freezer unit. The stacking apparatus or device is capable of automatically transposing articles from an end-to-end relationship along a path on a conveyor belt to a superposed relation in a plurality of neat stacks on a support. The invention also contemplates an apparatus for removing the stacks of articles and placing them into containers so that the articles are packaged for shipment and/or storage.

The method of the present invention for stacking the flat articles consists of continuing the movement of the articles from the end of a freezer unit in end-to-end relation and transversely spaced rows along a path, dropping the articles at the end of the path towards a support below the path, briefly interrupting the downward motion of the articles between the path and the support to stabilize the articles and finally form stacks of articles on the support in a stacking area. When a predetermined number of articles are located in the respective stacks, the full stacks are moved from the stacking area to a collection area on the support.

When a predetermined number of stacks are located in the collection area on the support, the stacks are placed in a container by guiding an opened topped and open ended shovel between the support and the stacks to simultaneously place a plurality of full stacks on the shovel. An open topped container is then positioned over the shovel with its open top facing downwardly and the container and shovel are clipped together so that they must be rotated as a unit to transfer the stacks of articles from the shovel to the container.

In its preferred form of the invention, the downward motion of the articles,when dropped from their path, is briefly interrupted by an intermediate shuttle plate that has an extended position where the plate is located in the stacking area at the end of the path and a retracted position removed from the stacking area. The shuttle plate is reciprocated between extended and retracted positions. Articles are received on the shuttle plate in seriatim, one above another, and a sensor counts the number of articles dropped from one or more rows at the end of the path to the plate. When a predetermined number of articles are located on the plate, the plate is reciprocated to the retracted position to allow the predetermined number of articles to form one or more stacks in the stacking area.

The movement of the articles from the stacking area may also be automatically controlled by sensing the number of articles dropped from the shuttle plate to the support and moving the stack of articles from the stacking area when a predetermined number of groups of articles is located in the stack.

In one embodiment of the invention, the distance the articles must drop from the shuttle plate before they are received on a stack is reduced by positioning a vertically movable platform in the stacking area and initially positioning the platform so that its upper surface is adjacent the shuttle plate. The platform is then lowered as the articles are received on the upper surface so that the distance of the free fall of the articles from the shuttle plate onto the stack is substantially reduced.

The apparatus for automatically stacking the articles consists of conveyor means for moving a plurality of articles in end-to-end relation along the path with guide means adjacent the end of the path for receiving the articles. A shuttle plate is located below the guide means and drive means periodically moves the shuttle plate from below the guide means to allow articles on the shuttle plate to drop and form stacks in the stacking area below the guide means.

In its preferred form, a plurality of articles are dropped onto the shuttle plate, one above-another, and the number of articles on the shuttle plate is determined by a counter means. When a predetermined number of articles is located on the shuttle plate, the counter means triggers actuation means for actuating the shuttle plate drive means to move the shuttle plate to its retracted position and allow the articles to drop and form stacks in the stacking area. The apparatus or device further includes means for automatically moving the stacks of articles from below the guide means in response to a predetermined number of groups of articles being dropped from the shuttle plate. This is accomplished by sending a signal to a signal responsive means each time the shuttle drive means is actuated and actuating a pusher plate drive means after receipt of a predetermined number of signals.

The plurality of stacks are moved by the pusher plate from the stacking area to a collection area on the support from which they are removed by a shovel means when a predetermined group of full stacks are located thereon.

The stacking and packaging a'pparatusalso includes means for preventing the stacks of articles from returning to the stacking area while the shovel is being in serted between the stacks and the support. In one embodiment, this means consists of a plurality of pins that are normally located above the support and are retracted each time stacks are removed from the stacking area.

In another embodiment, the apparatus for preventing the stacks from entering the stacking area consists of a vertically movable platform in the stacking area that also performs the additional function of reducing the distance of free fall for the articles from the shuttle plate before the articles come to rest in a stack in the stacking area. The platform has an upper surface which is initially in its uppermost position to locate the surface adjacent the shuttle plate. The platform is lowered as the articles are deposited in stacks on the surface and the pusher plate is actuated when the upper surface of the platform is in horizontal alignment with the support or table.

The packaging apparatus for removing the stacks of articles from the collection area includes an open topped and open ended shovel that is supported for universal movement above the support and for overturning or rotation about a horizontal axis. The support means for the shovel includes first and second frames that are guided for movement along perpendicular paths above the support or table. A first tube depends from the second frame and a second tube is telescoped in the first tube with counterweight means normally maintaining the two tubes in a collapsed condition. The shovel is supported for rotation about a horizontal axis at the lower end of the second tube.

The shovel support allows the shovel to be moved in any direction adjacent the table or support.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF DRAWINGS FIG. 1 is a perspective view, partly in section, of the stacking device and part of the packing device constructed in accordance with the present invention;

FIG. 2 is a perspective similar to FIG. 1 showing the first step in removing a plurality of stacks of articles from the collection area;

FIG. 2a schematically illustrates the manner of transferring the stacks of articles from the shovel to a container;

FIG. 3 shows the sealed package in its final configuration for storage and shipment;

FIG. 4 is an end view of the stacking and packaging area;

FIG. 5 is an overall plan view of the stacking and packaging area;

FIG. 6 is a side elevation view of the stacking and packaging area;

FIG. 7 is a vertical section through the stacking area;

FIG. 8 (appearing with FIG. 4) is a fragmentary plan view of the stacking area;

FIG. 9 is an enlarged section of the stacking area;

FIG. 10 is an end view, partly in section, of a modified version of the stacking area;

FIG. 11 is an enlarged section of the stacking area shown in FIG. 10; and

FIG. 12 is a schematic illustration of the control circuit that can be utilized with the stacking apparatus.

DETAILED DESCRIPTION While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail several embodiments, with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments illustrated.

Referring to FIGS. 1 and 2 there is shown a stacking device or apparatus, generally designated by the reference numeral 10, for receiving a plurality of articles from endless conveyor 12. In the specific embodiment illustrated, conveyor 12 is located within a chamber of a flash freezing unit 14 that freezes flat articles, such as hamburger patties. The articles emerge from the end of freezer unit 14 in end-to-end relation along a path in a plurality of transversely spaced rows. The articles are automatically converted from the end-to-end relation to a plurality of stacks S (FIG. 1) by stacking apparatus 10 and the plurality of stacks are moved onto table or support 20. The stacks of articles on the table are then readily enclosed in suitable containers by packaging apparatus, generally designated by the reference numeral 22.

Packaging apparatus 22 incorporates mechanism for removing a plurality of stacks from support 20 and positioning the stacks within container 24, which may be enclosed and sealed while being supported on table 26 and ultimately weighed on scale 28 before the container is moved to a storage area.

THE STACKING APPARATUS The articles stacking apparatus or device is most clearly shown in FIGS. 6 through 9. The stacking apparatus includes endless conveyor 30, which has its upper flight horizontally aligned with the upper surface of conveyor 12 located within freezer unit 14. Conveyor means 30 moves a plurality of transversely spaced rows of articles in end-to-end relation along a path defined by the upper flight of the conveyor means.

Guide means 32 are located at the end of the path for receiving the articles as they leave the end of conveyor means 30. The guide means appear most clearly in FIGS. 2, 7 and 9 and consist of inclined ramp 34 at the end of conveyor means 30 and a plurality of troughs or chutes 36 respectively aligned with the respective rows of articles on conveyor means 30. The chutes or troughs are illustrated as being rectangular in crosssectional configuration and are open at the top and the bottom.

The forward portion of guide means 32 (the portion remote from conveyor means 30) has a fixed portion 37 (FIG. 9) and a movable portion 37a that is connected to the fixed portion by hinge 38. The movable portion is normally biased to the position shown in FIG. 9 by spring 39, for a purpose that will be described later.

The stacking device further includes shuttle plate 40 that extends the entire width of the conveyor below guide means 32 with the shuttle plate having extended and retracted positions, respectively shown by the solid and dotted line positions in FIG. 9. In the extended position, shuttle plate 40 closes off the lower end of each of rectangular chutes 36. The shuttle plate is reciprocated between the extended and retracted positions (FIG. 9) by shuttle drive means 42 in the form of a fluid ram having its cylinder 44 secured to fixed support 46 and its piston rod 48 secured to the shuttle plate through support plate 50. When the shuttle plate is retracted the articles supported thereon drop onto support 20 that extends into the stacking area.

At predetermined intervals, pusher plate 60 moves the articles from the stacking area, defined below the guide means to produce a plurality of rows of stacks on support 20, in a collection area. Pusher plate 60 is reciprocated between retracted and extended positions by pusher plate drive means 61 which consists of piston rod 62 connected to plate 60 and cylinder 64 carried by fixed support 46. The retracted and extended positions are shown by the solid and dotted lines of FIG. 9.

The stacks of articles that have been moved out of I the stacking area are prevented from returning to the stacking area by retractable means 66, shown in FIGS. 7 through 9.. The retractable means consist of a plurality of transversely spaced pins 70 that extend through openings 72 in support or table and are fixed at their lower ends to angle plate 74. The plate has a pair of arms 76 (only one being shown) extending therefrom and pivoted at the outer ends on shaft 78 that is supported by brackets 79 on the lower surface of table 20. The transverse spacing between adjacent pairs 0 pins is less than the width of articles 16 so that the articles cannot be moved between the pins while the pins are in an extended position.

Pins 70 are moved between extended and retracted positions by a fluid ram which includes-cylinder 80 at tached tosupport 82 and having its piston rod 84 secured to .plate 74. Extension and retraction of piston rod 84 will cause the pins to move from an extended position above the table shown in FIGS. 7 and 9 to a retracted position below the upper surface of support 20.

In the operation of stacking device 10, the articles 16 are moved in end-to-end relation and transversely spaced rows along conveyor means 30. The articles are dropped at the end of the conveyor means into the respective chutes or guide means 36, defined at the end of each row of articles. The downward movement of the articles in the stacking area is then briefly interrupted by shuttle plate 40 to stabilize the articles before they are ultimately positioned in a stack on support 20.

Preferably, two or more articles are arranged in superposed relation to each other on the shuttle plate before the shuttle plate drive means is actuated. The shuttle plate drive means is automatically actuated when a predetermined group of articles has dropped from each row into the respective guides or chutes. The sensing means for determining the number of articles received on the shuttle plate is shown in FIG. 9 and consists of a photocell or sensing device 90, which contains its own light source and reflector 92 located in at least one of the guide chutes having opening 94 located in the front wall of the guide chute to allow the light from photocell 90 to be transmitted to the reflector.

Thus, as shown in FIG. 12, each time an article drops from the end of the path onto the shuttle plate, from the rows of articles having the sensing device associated therewith, photocell 90 produces a signal that is fed to counter means 96, which records the number of articles that are on the shuttle plate. When a predetermined number of articles are on the shuttle plate, counter means 96 sends a signal to an actuating means 98 for actuating shuttle drive means or fluid ram 42 and causes shuttle plate 40 to move from its extended position below the guide means to a retracted position to allow the articles to drop and form a stack in the stacking area below the guide means. Counter means 96 returns to its zero position when the shuttle plate is actuated to reset the counting cycle.

According to another aspect of the invention, the

stacks of articles are automatically moved from the stacking area when a predetermined number of articles is located in each stack in the stacking area. The number of articles in the stacks is recorded by sending a signal from counter means 96 to counter means 100 each time the shuttle plate is actuated. Counter means 100 records the signals received and actuates a signal responsive means or valve 102 after receipt of a predetermined number of signals, to activate pusher plate drive means 61 and move the stacks from the stacking area to a collection area on support 20. Counter means 100 returns to its zero position when the pusher plate drive means is actuated. According to another aspect of the invention, the number of articles required for actuating the shuttle drive means and the pusher plate drive means is readily reset so that any number of articles can be produced in the stack. For this purpose, counter means 96 has knob 104 that is rotatable to set the number of articles that must move past photocell before the shuttle plate is retracted. Also, counter means has knob 106 to set the total number of articles in the stack required for actuation of the pusher plate. Assuming for example, 15 articles are to be placed in superposed relation in stacks, counter means 96 could be set, for example, at three, while counter means 100 could be set at five. With such a setting, when three articles are located on the shuttle plate, the shuttle plate is actuated to deposit the groups of three articles in each row onto the support in the stacking area. After five groups of articles are arranged in superposed relation in each row in the stacking area, counter means 100 will send a signal to valve 102 to actuate pusher plate drive means 61 and move the stacks of articles from the stacking area.

Just prior to having the articles moved from the stacking area, it is necessary for pins 70 to be moved to the retracted position below the upper surface of support 20. It is also necessary to allow sufficient time after movement of shuttle plate 40 to its retracted position to allow the articles to be dropped and stabilize on the stacks before the stacks are moved from the stacking area. This is accomplished by actuating control device or valve 110 to retract pins 70 at the time the counter means produces an output signal. A slight time delay is produced by time delay 112 before control valve 102 is actuated so that the articles can be deposited and stabilized on the stack and pins 70 retracted before the pusher plate is actuated.

MODIFIED STACKING DEVICE A slightly modified form of stacking device is shown in FIGS. 10 and 11, which is in many respects similar to the device described above. Therefore, common reference numerals have been utilized for common parts and only the changes will be described in detail.

In the modified form of the invention, the retractable means extending above the flat support for preventing the full stacks of articles from returning to the stacking area also performs the function of reducing the distance of free fall of the articles from the shuttle to the support. This is accomplished by forming an opening in support 20 in the stacking area. Vertically movable platform 142 is positioned below the opening and has an upwardly extended portion 144 extending through opening 140 with an upper surface 146 positioned below the guide means. As more clearly shown,

in FIG. 10, vertically extending portion 144 consists of a plurality of tubes 148 that have their upper ends terminating in a common horizontal plane to define upper surface 146. Platform 142 and its upperwardly extending portion 144 are vertically movable by fluid ram 150 having its piston rod 152 connected to platform 142 and its cylinder 154 secured to a base portion 156 of the frame for the table.

In the modified form of stacking apparatus, upper surface 146 of the platform is initially positioned adjacent the shuttle plate by extending piston rod 152. As each group of articles is dropped onto the upper surface by retracting shuttle plate 40, the vertically movable platform is lowered to be able to receive the next group of articles. It will be noted that while the platform is in any position other than the completely lowered position, the side walls of the tubes 148 will prevent the previously pushed out full stacks of articles from re-entering the stacking area.

PACKAGING APPARATUS The packaging apparatus 22 is most clearly shown in FIGS. 2, 2a, 4 and 6. The packaging apparatus consists of a shovel 200 that is suspended below the support for universal movement relative to flat support 20. The support means for suspending the shovel include first frame 202 guided for reciprocal movement, in opposite directions, along first rail means or guides 204. The direction of movement is indicated by arrows 206 and the frame is supported on the rail means by rollers 208.

The means for suspending the shovel further includes second frame 210 that is guided on second rail means 212 by rollers 213. Second rail means 212 are formed on the first frame so that the second frame can move in opposite directions along a path that is perpendicular to the path of the first rail means. The direction of movement of the second rail means is indicated by arrows 214.

The shovel support means also includes first tube 220 secured to second frame 210 and depending therefrom. Second tube 222 is telescoped within the first tube and has tubular sleeve 224 secured or supported on the lower end thereof. The sleeve has an elongated opening that has its axis extending perpendicular to the axis of the tube and shovel 200 has handle 226 which has a portion that is rotatably supported in tubular sleeve 224.

The means for suspending the shovel also includes counterweight means secured to the second tube and movably supported on the second frame for normally maintaining the first and second tubes in a collapsed condition. The counterweight means is most clearly illustrated in FIG. 6 and includes counterweight 230 that is guided within tube 232 carried by bracket extension 234 that extends from first tube 220. Counterweight 230 has a total weight that is approximately equal to the second tube, shovel and a container full of articles so that the weight will be balanced when the shovel is filled with articles. When the shovel is empty, the counterweight will maintain the first and second tubes in a collapsed condition. Tube 222 and counterweight 230 are connected by cable 236 which passes over pulleys 238.

It is also desirable to transversely divide support into segments that are substantially equal to the transverse width of the shovel so that the shovel can easily be guided between support surface 20 and the stack of articles. For this purpose, flat support 20 has a plurality of transversely spaced separators or dividers 240 extending above the support to divide the stacks into a plurality of groups. Each group of stacks has a plurality of transversely spaced stacks and the spacing between the separators is such that the shovel can readily be guided between adjacent separators for picking all of the stacks between a pair of adjacent separators.

OPERATION In packaging articles with the apparatus of this invention, a source of fluid under pressure, such as air, is supplied to each valves 98, 102, and conveyor means 30 is actuated. The conveyor may be driven by a suitable electric motor (not shown) or other type of drive means. An electrical energy source is connected to the device to provide the necessary power for the electrical components of the circuit.

The articles emerging from the end of freezer unit 14 in transversely spaced rows and in end-to-end relationship are received on conveyor means 30 and are dropped at the end of the path defined by conveyor means 30. Each time an article drops into the guide chute having the photocell associated therewith, the photocell feeds a signal to the first counter means. When a predetermined number of articles are on shuttle plate 40, determined by the setting of knob 104, control valve 98 is actuated to retract piston rod 48 and shuttle plate 40 to allow the articles to drop in the stacking area and form a plurality of stacks.

In the embodiment illustrated in FIGS. 7, 8 and 9 the articles are dropped directly onto support 20 to form the stacks in the stacking area. In the embodiment illustrated in FIGS. 10 and 11, the platform is initially positioned so that upper support surface 146 is located adjacent the shuttle plate and the spacing is approximately equal to the height of the number of articles that are dropped from the shuttle plate, each time the shuttle plate is actuated. In this embodiment, each time the shuttle plate is actuated, control valve 160 is likewise actuated to lower the platform an amount sufficient so that the next group of articles to be dropped can be received onto the platform, below the shuttle plate.

When a predetermined number of groups of articles are located in each of the stacks, determined by setting of counting means 100, the counter means actuates control valve 110 and activates timer 112 so that pins 70 are retracted and valve 102 is subsequently actuated to move the plurality of stacks of articles from the stacking area to the collection area on the support. In the modified embodiment of FIGS. 10 and 11, the platform is at this time in a position where upper surface 146 is located in horizontal alignment with upper surface 20.

The above operation is repeated until a plurality of stacks of articles are located in the collection are on the support. At selected times, shovel 200 is lowered and positioned so that the bottom of the shovel engages support 20 and the shovel is transversely aligned so as to be movable between an adjacent pair of separators 240. The shovel is then moved to a position shown in FIG. 2 to locate a plurality of stacks S on the shovel. Container 24 is then positioned over the open topped shovel and the shovel and container are held together by a clip C, as is shown in FIG. 2a. The container and shovel are then overturned or rotated substantially and positioned on the table 26, as is shown in FIG.

2a. The clip can then be removed and the shovel raised so that the container may be closed and sealed and moved to the weighing station 28.

The packaging operation is repeated by removing a plurality of stacks of articles from a position between the next adjacent pair of separators on the support.

It will be appreciated that the apparatus and method described herein allows a single operator to stack and package all of the articles that emerge from the end of a freezer unit.

It would be noted that at times there may be a malfunction in stacking and packaging apparatus. In these instances, conveyor means 30 are pivoted to the dotted line position of FIG. 6 and a suitable collector or conveyor may be located below the end of conveyor 12 to receive the articles while the stacking and packaging apparatus is repaired.

Many variations may be made to the apparatus without departing from the spirit of the present invention.

For example, the stacking apparatus may be utilized with any other means for supplying the articles in endto-end relation and the freezer unit has been shown for illustrative purposes only.

Also, the packaging apparatus has separate utility without regard to the specific stacking apparatus disclosed herein. In addition, either stacking apparatus could be utilized separately and the stacks of articles could be packaged by other means, such as by hand.

It is also to be noted that although sub-assembly 22 has been termed packaging apparatus in this description, it need not be used for packaging. If it were desired, for example, to store the stacked articles on pallets rather than pac kage them in container, an upsidedown pallet could be substituted for container 24 in FIG. 2, the upper surface of the pallet taking the place of the container bottom as the supporting surface for the stacks when the shovel is rotated to the position shown in FIG. 2a.

If desired, tubes 144 could be open at the top to provide an extension of the guide means. In this instance, the open top tubes would extend through annular openings in support 20 and would'receive the plurality of articles. Each time a full stacks is to be removed, the tubes would be retracted to expose the articles. The closed tubes shown in FIGS. and 11 could be replaced with plates to define a continuous upper surface 146.

It would also be noted that while the shuttle plate has been moved to a retracted position under conveyor means 30, the shuttle plate could be moved in the opposite direction or moved transversely of the conveyor, if desired.

Another feature that could readily be modified is the sensing mechanism for the counting of the number of articles that are received on the shuttle plate. In the illustrated embodiment, a single photocell has been shown. However, a separate photocell could be supplied for each row of articles so that each article received onto the shuttle plate could be counted. The various photocells could then feed signals to counter means 96 and the counter means could be designed to be actuated only when an appropriate number of signals have been received from all of the photocells. This In another modification, photoelectric sensor 90 may be of a type which responds to the continued absence of a reflected signal from reflector 92 rather than the instantaneous absence of a reflected signal produced by a dropping article. In this case, the number of articles within a chute over the shuttle plate will be determined by the height of the stack on the shuttle plate, the height of sensor 90 and reflector 92 being adjustable to the desired height of the stack. In this case no counter is required.

Similarly, the pusher plate mechanism and the retraction of pins may be adjusted, if desired, by a photoelectric sensor system which measures the height of the stacks in the stacking area.

I claim:

1. A method of packaging a plurality of flat articles comprising the steps of arranging the articles in superposed relation to each other in a plurality of stacks at a stacking area on a support; guiding an open topped shovel between said support and said stacks to support said stacks on said shovel; positioning a supporting surface over said shovel and stacks to locate said stacks in a substantially fixed position between opposing portions of said shovel and supporting surface; and overturning said supporting surface and shove] to place said stacks of articles on said supporting surface.

2. A method as defined in claim 1, in which said supporting surface is the bottom of an open topped container with the open top facing downwardly prior to said overturning to enclose said stacks of articles between said container and shovel.

3. A method as defined in claim 1, in which the step of arranging includes moving the articles in end-to-end relation along a path in transversely spaced rows above said support; and dropping each row into a stack on said support in the stacking area.

4. A method as defined in claim 3, including the further step of briefiy interrupting the downward movement of the articles between said path and said support to stabilize said articles before they are dropped onto the support to form stacks 5. A method as defined in claim 4, in which the step of interrupting the downward movement of the articles includes placing a shuttle plate in an extended position between said path and said support in the stacking area to collect a predetermined number of said articles on said plate, periodically withdrawings said plate to a retracted position to allow said predetermined number of articles to be deposited in stacks below said plate, and periodically moving said stacks from below said plate along said support.

6. A method as defined in claim 4, further including placing a platform having an upper surface in the stacking area; initially positioning the platform so that said upper surface is above said support adjacent the shuttle plate; lowering said platform as the articles are received on said upper surface; moving the stacks of articles off the upper surface when the upper surface is aligned with said support; and returning the upper surface to a position above said support adjacent the shuttle plate.

7. A method as defined in claim 4, periodically moving the stacks from the stacking area; and preventing the stacks of articles from re-entering the stacking area while the shovel is guided between said support and said stacks.

8. A method of packaging articles comprising the steps of moving a plurality of articles in end-to-end relation along a path to a stacking area; dropping said articles from the end of said path onto an intermediate shuttle plate in the stacking area at the end of said path; periodically withdrawing the intermediate shuttle plate from the end of said path to drop the articles in a stack onto a lower support; moving said stack of articles from the stacking area when a predetermined number of articles is located in said stack; periodically interposing an open topped and open ended shovel between said flat surface and the stacks of articles to support the stacks of articles on said shovel; positioning an open topped container over said shovel with the open top facing downwardly; and overturning said shovel and container to place the stacks of articles in the container.

9. A method of packaging articles as defined in claim 8, including the steps of sensing the number of articles dropped from the end of said path; withdrawing said shuttle plate when a predetermined group of articles is located on said shuttle plate; sensing the number of groups of articles dropped from said shuttle plate; and moving the stack of articles from the stacking area when a predetermined number of groups of articles are in said stack.

10. A method of packaging as defined in claim 9, in which there are a plurality of transversely spaced rows of articles moving along said path to simultaneously produce a plurality of stacks in the stacking area with all of said stacks simultaneously removed from the stacking area, further including dividing said stacks into first and second groups on said support and subsequently removing a plurality of stacks from each group with said shovel.

11. A method of stacking a plurality of fiat articles comprising the steps of moving a plurality of articles in end-to-end relation along side-by-side paths in transversely spaced rows; dropping said articles at the end of said paths toward a support below said plates; briefly interrupting the downward motion of the articles between the paths and support to stabilize the articles thereby forming a plurality of stacks of articles on the support in a stacking area; moving the stacks from the stacking area when a predetermined number of articles are located in the stacks; guiding an open topped shovel between said stacks and support to support said stacks on said shovel; positioning an open topped container over said shovel with the open top facing downward to enclose a plurality of stacks between said container and shovel; and rotating said container and shovel to place said stacks in said container.

12. A method as defined in claim 11, the further step of preventing the full stacks of articles from returning to the stacking area while the shovel is positioned between the stacks and the support.

13. A flat articles stacking device comprising means for moving a plurality of articles in end-to-end relation along a path; a shuttle plate at the end of said path for receiving a group of articles from said path at a stacking area; guide means above said shuttle plate for guiding said articles onto said plate; shuttle drive means for periodically moving said shuttle plate from below said guide means to drop said articles and form a stack at the stacking area below said guide means; a pusher plate below said guide means adjacent said stack; pusher plate drive means for periodically moving said pusher plate between first and second positions to move said stack from below said guide means; a flat support for receiving said stacks; a shovel for simultaneously removing a plurality of stacks from said support and depositing said stacks in a container; and means above said support for suspending said shovel for universal movement relative to said flat support.

14. A device as defined in claim 13, in which said means above said support includes a first frame; first rail means for guiding said first frame in opposite directions along a first path; a second frame; second rail means on said first frame for guiding said second frame in opposite directions along a second path perpendicular to said first path; a depending first tube secured to said second frame; a second tube telescoped relative to said first tube; and means for supporting said shovel on said second tube.

15. A device as defined in claim 14, in which said means for supporting said shovel includes a tubular sleeve supported on the lower end of said second tube, said sleeve having its axis extending perpendicular to the axis of said second tube; and a handle secured to said shovel and rotatably supported in said tubular sleeve.

16. A device as defined in claim 15, in which said second tube is rotatable relative to said first tube, further including counterweight means secured to said second tube and movably supported on said second frame, said counterweight means having a weight greater than the combined weight of said second tube, shovel, sleeve and handle.

17. A device as defined in claim 13, retractable means normally extending above said flat support adjacent the stacking area, said retractable means preventing full stacks of articles from re-entering the stacking area when said plurality of stacks are being removed from said flat support.

18. A flat device as defined in claim 13, in which there are a plurality of transversely spaced rows of articles moving in end-to-end relation on along said path simultaneously produce a plurality of stacks, further including a plurality of transversely spaced separators extending above said flat support to divide the stacks into a plurality of groups with each group having a plurality of transversely spaced stacks and in which said shove] has a transverse dimension substantially equal to the spacing between adjacent separators to simultaneously remove a plurality of groups of stacks.

19. Apparatus for packaging a plurality of articles arranged in a plurality of stacks comprising a support adapted to receive a plurality of articles; a shovel; support means for suspending said shovel for universal movement above said support, said support means including means for supporting said shove] for rotation about a horizontal axis above said support, said shovel having an open top and open end; and counterweight means on said support means for maintaining said shovel in a raised position, said shovel being dimensioned to receive an open topped container of corresponding size so that (1) said shovel may be guided along an upper surface on said support to place a plurality of stacks of articles on said shovel, (2) a container may be placed over the shovel and (3) the container and shovel may be overturned to place the articles in the container.

20. Apparatus as defined in claim 19, in which said support includes a fixed frame above said support first scoped in the lower end of said first tube with said counterweight means normally maintaining said tubes in telescoping relation in said first tube and in which said means for supporting said shovel for rotation includes a sleeve on the lower end of said second tube, said sleeve defining an elongated horizontal opening;

and a handle on said shovel rotatable in said opening. 

1. A method of packaging a plurality of flat articles comprising the steps of arranging the articles in superposed relation to each other in a plurality of stacks at a stacking area on a support; guiding an open topped shovel between said support and said stacks to support said stacks on said shovel; positioning a supporting surface over said shovel and stacks to locate said stacks in a substantially fixed position between opposing portions of said shovel and supporting surface; and overturning said supporting surface and shovel to place said stacks of articles on said supporting surface.
 2. A method as defined in claim 1, in which said supporting surface is the bottom of an open topped container with the open top facing downwardly prior to said overturning to enclose said stacks of articles between said container and shovel.
 3. A method as defined in claim 1, in which the step of arranging includes moving the articles in end-to-end relation along a path in transversely spaced rows above said support; and dropping each row into a stack on said support in the stacking area.
 4. A method as defined in claim 3, including the further step of briefly interrupting the downward movement of the articles between said path and said support to stabilize said articles before they are dropped onto the support to form stacks.
 5. A method as defined in claim 4, in which the step of interrupting the downward movement of the articles includes placing a shuttle plate in an extended position between said path and said support in the stacking area to collect a predetermined number of said articles on said plate, periodically withdrawings said plate to a retracted position to allow said predetermined number of articles to be deposited in stacks below said plate, and periodically moving said stacks from below said plate along said support.
 6. A method as defined in claim 4, further including placing a platform having an upper surface in the stacking area; initially positioning the platform so that said upper surface is above said support adjacent the shuttle plate; lowering said platform as the articles are received on said upper surface; moving the stacks of articles off the upper surface when the upper surface is aligned with said support; and returning the upper surface to a position above said support adjacent the shuttle plate.
 7. A method as defined in claim 4, periodically moving the stacks from the stacking area; and preventing the stacks of articles from re-entering the stacking area while the shovel is guided between said support and said stacks.
 8. A method of packaging articles comprising the steps of moving a plurality of articles in end-to-end relation along a path to a stacking area; dropping said articles from the end of said path onto an intermediate shuttle plate in the stacking area at the end of said path; periodically withdrawing the intermediate shuttle plate from the end of said path to drop the articles in a stack onto a lower support; moving said stack of articles from the stacking area when a predetermined number of articles is located in said stack; periodically interposing an open topped and open ended shovEl between said flat surface and the stacks of articles to support the stacks of articles on said shovel; positioning an open topped container over said shovel with the open top facing downwardly; and overturning said shovel and container to place the stacks of articles in the container.
 9. A method of packaging articles as defined in claim 8, including the steps of sensing the number of articles dropped from the end of said path; withdrawing said shuttle plate when a predetermined group of articles is located on said shuttle plate; sensing the number of groups of articles dropped from said shuttle plate; and moving the stack of articles from the stacking area when a predetermined number of groups of articles are in said stack.
 10. A method of packaging as defined in claim 9, in which there are a plurality of transversely spaced rows of articles moving along said path to simultaneously produce a plurality of stacks in the stacking area with all of said stacks simultaneously removed from the stacking area, further including dividing said stacks into first and second groups on said support and subsequently removing a plurality of stacks from each group with said shovel.
 11. A method of stacking a plurality of flat articles comprising the steps of moving a plurality of articles in end-to-end relation along side-by-side paths in transversely spaced rows; dropping said articles at the end of said paths toward a support below said plates; briefly interrupting the downward motion of the articles between the paths and support to stabilize the articles thereby forming a plurality of stacks of articles on the support in a stacking area; moving the stacks from the stacking area when a predetermined number of articles are located in the stacks; guiding an open topped shovel between said stacks and support to support said stacks on said shovel; positioning an open topped container over said shovel with the open top facing downward to enclose a plurality of stacks between said container and shovel; and rotating said container and shovel to place said stacks in said container.
 12. A method as defined in claim 11, the further step of preventing the full stacks of articles from returning to the stacking area while the shovel is positioned between the stacks and the support.
 13. A flat articles stacking device comprising means for moving a plurality of articles in end-to-end relation along a path; a shuttle plate at the end of said path for receiving a group of articles from said path at a stacking area; guide means above said shuttle plate for guiding said articles onto said plate; shuttle drive means for periodically moving said shuttle plate from below said guide means to drop said articles and form a stack at the stacking area below said guide means; a pusher plate below said guide means adjacent said stack; pusher plate drive means for periodically moving said pusher plate between first and second positions to move said stack from below said guide means; a flat support for receiving said stacks; a shovel for simultaneously removing a plurality of stacks from said support and depositing said stacks in a container; and means above said support for suspending said shovel for universal movement relative to said flat support.
 14. A device as defined in claim 13, in which said means above said support includes a first frame; first rail means for guiding said first frame in opposite directions along a first path; a second frame; second rail means on said first frame for guiding said second frame in opposite directions along a second path perpendicular to said first path; a depending first tube secured to said second frame; a second tube telescoped relative to said first tube; and means for supporting said shovel on said second tube.
 15. A device as defined in claim 14, in which said means for supporting said shovel includes a tubular sleeve supported on the lower end of said second tube, said sleeve having its axis extending perpendicular to the axis of said second tube; anD a handle secured to said shovel and rotatably supported in said tubular sleeve.
 16. A device as defined in claim 15, in which said second tube is rotatable relative to said first tube, further including counterweight means secured to said second tube and movably supported on said second frame, said counterweight means having a weight greater than the combined weight of said second tube, shovel, sleeve and handle.
 17. A device as defined in claim 13, retractable means normally extending above said flat support adjacent the stacking area, said retractable means preventing full stacks of articles from re-entering the stacking area when said plurality of stacks are being removed from said flat support.
 18. A flat device as defined in claim 13, in which there are a plurality of transversely spaced rows of articles moving in end-to-end relation on along said path simultaneously produce a plurality of stacks, further including a plurality of transversely spaced separators extending above said flat support to divide the stacks into a plurality of groups with each group having a plurality of transversely spaced stacks and in which said shovel has a transverse dimension substantially equal to the spacing between adjacent separators to simultaneously remove a plurality of groups of stacks.
 19. Apparatus for packaging a plurality of articles arranged in a plurality of stacks comprising a support adapted to receive a plurality of articles; a shovel; support means for suspending said shovel for universal movement above said support, said support means including means for supporting said shovel for rotation about a horizontal axis above said support, said shovel having an open top and open end; and counterweight means on said support means for maintaining said shovel in a raised position, said shovel being dimensioned to receive an open topped container of corresponding size so that (1) said shovel may be guided along an upper surface on said support to place a plurality of stacks of articles on said shovel, (2) a container may be placed over the shovel and (3) the container and shovel may be overturned to place the articles in the container.
 20. Apparatus as defined in claim 19, in which said support includes a fixed frame above said support first rail means on said fixed frame defining a first path; a first movable frame supported on said fixed rail means; second rail means on said first frame defining a second path perpendicular to said first path; a second frame guided on said second rail means; and means on said second frame supporting said shovel.
 21. Apparatus as defined in claim 20, in which said means on said second frame includes a first depending tube carried by said second frame; a second tube telescoped in the lower end of said first tube with said counterweight means normally maintaining said tubes in telescoping relation in said first tube and in which said means for supporting said shovel for rotation includes a sleeve on the lower end of said second tube, said sleeve defining an elongated horizontal opening; and a handle on said shovel rotatable in said opening. 